Mazda Protege 2002 2003 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Protege Model Years Covered: 2002, 2003 Codes Chassis Code General: BJ 👋 Introduction Market Position Target Audience: Do-it-yourself owners and experienced mechanics Competitive...

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类型: Car

斯库: 14165

标签: 2002 2003 Car Engines K Series Mazda Protege

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Protege

Model Years Covered:

2002, 2003

Codes

Chassis Code General:

👋 Introduction

Market Position

Target Audience:

Do-it-yourself owners and experienced mechanics

Competitive Analysis

Value Proposition:

Inexpensive way to keep vehicle working properly, replaces expensive factory service manuals or professional mechanic fees

Key Features

Content Highlight:

Complete official full factory service repair manual

Delivery Method:

Instant download after purchase

Visual Aid Emphasis:

Hundreds of photos, illustrations, drawings, and enlarged insets

Organization:

Numbered table of contents for fast information retrieval

📋 Manual Details

Coverage Areas

Regional Coverage:

Global (based on common factory service manual structure)

Page Count

Estimated Page Count:

Hundreds (specific count not provided, but implies comprehensive coverage)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, crankshaft, pistons, connecting rods, lubrication system, cooling system, timing systems (belt/chain), fuel delivery (injection/carburetion, if applicable)

Engine Management:

Ignition system, fuel injection system, emissions control systems, engine control module (ECM/ECU) operation, sensors and actuators, diagnostic trouble codes (DTCs), powertrain control

Transmission Manual:

Manual transmission assembly, disassembly, clutch system, shifting mechanisms, gear ratios, lubrication

Transmission Automatic:

Automatic transmission assembly, disassembly, torque converter, hydraulic control systems, electronic controls, gear selection, lubrication

Drivetrain:

Front-wheel drive (FWD) system, axles, CV joints, differential (if integrated with transmission)

Suspension:

Front suspension (e.g., MacPherson strut), rear suspension (e.g., multi-link), shock absorbers, springs, control arms, bushings, alignment specifications

Steering:

Power steering system (hydraulic/electric), steering rack, steering column, tie rods, steering wheel assembly, alignment specifications

Brakes:

Front disc brakes, rear disc/drum brakes, hydraulic system, brake lines, calipers, rotors, pads, parking brake system, ABS (Anti-lock Braking System) components and diagnostics

Electrical System:

Battery, charging system (alternator, starter), ignition switch, lighting system (headlights, taillights, interior), horns, wipers, power windows, central locking, fuse boxes, relays

Body And Chassis:

Body panel removal and installation, door mechanisms, hood, trunk lid, bumpers, interior trim, underbody protection, structural components

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant circuits, blower motor, climate control unit, dash vents, heater core, evaporator core

Safety Systems:

Airbag system components, SRS (Supplemental Restraint System) diagnostics and calibration, seat belts

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement

Troubleshooting:

Diagnostic procedures for common drivability issues, electrical faults, starting problems, cooling system issues, brake system malfunctions

Repair And Rebuild:

Step-by-step instructions for component disassembly, repair, and reassembly (e.g., engine rebuild, transmission overhaul, brake caliper replacement)

Diagnostics:

Fault code interpretation, component testing procedures (resistance, voltage, current), sensor diagnostics, actuator testing

Wiring Diagrams:

Detailed electrical wiring schematics for various vehicle systems, including power distribution, ground points, and component connections

Specifications:

Torque specifications for fasteners, fluid capacities and types, alignment settings, electrical resistance values, pressure specifications

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

Detail Level:

Hundreds of photos and illustrations, detailed substeps, notes, cautions, and warnings

📊 Manual Specifications

File Format

Format:

Compatibility:

All PC based Windows operating systems and Mac

Print Quality

Printability:

Printable without any restriction (entire manual or selected pages)

Binding Type

Binding:

Digital (downloadable PDF, printable)

Paper Type

Paper Type:

N/A (digital format)

Software Requirements

Reader Requirement:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Engine Options 2002 2003:

1.6L 4-Cylinder (Z5-DE), 2.0L 4-Cylinder (FS-DE, FS-ZE for Mazdaspeed Protege)

Performance

1.6L Horsepower Approx:

105 hp @ 6000 rpm

1.6L Torque Approx:

104 lb-ft @ 4000 rpm

2.0L Fs-De Horsepower Approx:

120-130 hp @ 6000 rpm (depending on market/tune)

2.0L Fs-De Torque Approx:

130-135 lb-ft @ 4000-4500 rpm (depending on market/tune)

2.0L Fs-Ze Mazdaspeed Horsepower Approx:

170 hp @ 6600 rpm

2.0L Fs-Ze Mazdaspeed Torque Approx:

145 lb-ft @ 5000 rpm

Fuel System

Fuel Injection Type:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Cooling System

Cooling Type:

Pressurized liquid cooling system

Engine Management

Ignition System:

Electronic ignition with Distributorless Ignition System (DIS) or Coil-on-Plug (COP)

🔧 Transmission

Standard

Standard Transmission Type:

5-speed manual transmission

Optional

Optional Transmission Type:

4-speed automatic transmission (with electronic control)

Features

Clutch Type:

Hydraulically actuated diaphragm spring clutch

Transmission Fluid Manual:

API GL-4 SAE 75W-90 or equivalent (specific part numbers will be in the manual)

Transmission Fluid Automatic:

ATF Dexron III or equivalent (specific part numbers will be in the manual)

📐 Dimensions

Exterior

Body Styles:

4-door Sedan, 5-door Hatchback

Weights

Curb Weight Approx:

2500-2800 lbs (depending on body style and equipment)

Gross Vehicle Weight Rating Approx:

3500-3800 lbs (depending on configuration)

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating:

4-star driver, 4-star passenger (for 2002 model sedan)

IIHS Offset Frontal Crash Rating:

Good (for 2002 model sedan)

Active Features

Anti Lock Brakes:

Available (ABS) on most trims

Passive Features

Airbags:

Standard front airbags for driver and passenger

Seatbelts:

3-point front and rear seatbelts

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional premium audio system

Driver Assistance

Cruise Control:

Available on most trims

Connectivity

Auxiliary Input:

Not standard, aftermarket solutions available

🔧 Maintenance

Service Intervals

Oil Change Interval:

Approximately 5,000 - 7,500 miles or 6-12 months (refer to manual for specific engine/oil type)

Air Filter Replacement:

Approximately 15,000 - 30,000 miles or as needed based on operating conditions

Spark Plug Replacement:

Approximately 60,000 - 100,000 miles for iridium plugs, less for conventional (check manual)

Timing Belt Replacement:

Approximately 60,000 - 90,000 miles (critical maintenance item for interference engines)

Fluid Specifications

Engine Oil Type:

API SN/SP, ILSAC GF-5 or newer, SAE 5W-20 or 5W-30 (check owner's manual for exact viscosity and specification)

Coolant Type:

Mazda FL22 or equivalent HOAT (Hybrid Organic Acid Technology) long-life coolant (typically green or blue)

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Known Issues

Common Engine Issue 1:

Oil consumption in higher mileage FS-DE engines

Common Suspension Issue 1:

Worn control arm bushings leading to clunks or imprecise handling

Common Electrical Issue 1:

Failing alternator or starter motor

Common Exhaust Issue 1:

Corrosion or leaks in the exhaust system, particularly in rust-prone areas

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Known for sporty handling and value-oriented vehicles

Model Evolution

Protege Generation Bj:

This generation (BJ) was introduced in 1998/1999 and received a significant facelift for the 2001 model year, with minor updates leading into 2002-2003.

Production

Manufacturing Location:

Primarily Japan, but also other global locations depending on market

Mazdaspeed Variant:

Introduced for the 2003 model year, featuring a turbocharged 2.0L engine and sport-tuned suspension.

🏆 Awards & Recognition

Recognitions

Car And Driver Awards:

Often recognized by Car and Driver for its sporty handling and value in its class during its production years.